Computer Applications in Manufacturing Systems, 2009

Department of Mechanical and Manufacturing EngineeringFaculty of Engineering

KMP 5701Computer Applications in Manufacturing Systems

Lecturer : Dr. Faeiza Abdul Aziz

Group A1

Name Matric No.

1. Mohammad Jamil Mohamed Ashraf GS23966

2. Firdaus Mohamed Sahid GS23988

3. Syahiran Desa GS23980

4. Khairil Inawan Mohammed GS23974

5. Rodzidah Mohd Rodzi GS23997

6. Mohd Nurhidayat Zahelem GS23991

Group A1

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F

A Review of Current Trend in e-ManufacturingFirdaus Mohamed Sahid, Mohammad Jamil Mohamed Ashraf, Khairil Inawan Mohammed,

Syahiran Desa, Rodzidah Mohd Rodzi, Mohd Nurhidayat.

Abstract

With a rapid change in technology especially inthe manufacturing sector, customers aredemanding more value, less risk, and betterintegration of products, hence there is a need tochange the manufacturing strategies, which canresult in improved performance thereby meetingthe customer demands. This paper reviews acurrent trend to overcome the above problemcalled “e–Manufacturing” which can integratecustomers, products and suppliers with the helpof Internet Technology. The concept of e-Manufacturing, its development, tools andpotential benefits are discussed. Areas like e–Maintenance, e-Diagnostics, e–Business relatedto e–Manufacturing is also discussed. Byadopting such a manufacturing technique zerodowntime, reduced product error, customersatisfaction, quick manufacturing changes canbe accomplished.

Keywords : e–Manufacturing, e-Business,e-Intelligence, e–Maintenance,e–Diagnostics.

I. INTRODUCTION

or today’s manufacturing companies what matters more is that how efficiently theircompany can compete globally with others as anorganization followed by meeting the day to dayrequirements of the customer and exchange ofhassle free information while not focusing onlyon sales of the company. Refer to Lee J, Ni J.E-manufacturing and e-business integration:a case study. Proceeding of the International

Manufacturing Leaders Forum (IMLF),Adelaide, Australia, February 8–10, 2002,Today’s customers provide top priority formoney, better quality and less risk. In order tocater to the needs of the customer,manufacturing companies have adopted a newtechnique called e-Manufacturing. It isconcerned with the use of the Internet and e-Business technologies in manufacturingindustries wherein a network can be establishedbetween the customer, the manufacturer and theproduct. The internet offers a frictionless pathfor exchange of information.

Studied by Koc M, Ni J, Lee J in the“Introduction of e-manufacturing.Proceeding of the International Conferenceon Frontiers on Design and Manufacturing”,Dalian, China, July 2002, The concepts of e-Maintenance, e-Business, e-Diagnostics and e-Care have led to the formation of an e-Factorywhich can produce quality products atremarkable speeds. In short, the customer is justa click away from a business deal. Withinmanufacturing concerns, the various enterprise-wide systems like ERP, MES, SCADA, andeven newer acronyms like Enterprise AssetManagement (EAM) and Product LifecycleManagement (PLM) are communicating witheach other, and sharing data through internetconnections.

II. EVOLUTION OF E-MANUFACTURING

For decades, the dominant manufacturing modelwas based on principles of mass production.Standardized parts and processes made

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economies of scale achievable, but limiteddesign flexibility and customization. Theoutsourcing and lean manufacturing movementsof the 1980s and 1990s drove the emergence ofa new paradigm, termed the QualityManagement era. Manufacturing companies,particularly large Original EquipmentManufacturers’ (OEM) outsourcing shiftscritical elements of the design and productionprocess onto a manufacturer’s supply chain. Thelean manufacturing movement places apremium on time and inventory reduction.Combining the attributes of the Quality erasuggests a very different business model formanufacturing – enterprise integration or e-Manufacturing. In the e-Manufacturing era,companies will be able to exchange informationof all types with their suppliers at the speed oflight.

New technologies such as the ExtensibleMarkup Language (XML) are now making iteasier to share data between differentapplication programs, and to set up computers totake actions based on criteria, to order supplieswhen inventories reach a critical low point. Thee-Manufacturing technique also affects productsas well since it is possible to use Internettechnologies to add new product functions andto provide new services.

Based on the book entitle “Exploiting EManufacturing: Interoperability of SoftwareSystems used by US Manufacturing “National Coalition for AdvancedManufacturing, 2001, pp 1-13, the Internet isbeing used even at the shop floor level. Forinstance, computer numerical control devices(CNC’s) can be connected via intranets or theInternet to ERP (Enterprise Resource Planning),production planning, or maintenance systems.As such, the e-Manufacturing project aims todevelop an appropriate framework for acommon platform to enable distributed planningand control in manufacturing for quicker, easier,secure and cost-effective collaborations. Thedeveloped system will allow dispersedengineering team members to work together

productively, as if they were under one roof.This transformation of the enterprise coincideswith the increasing content of informationcontained in products and processes. This newproduction enterprise is information-rich.

Adapted from a Journal “Making sense of E-Manufacturing: A Road map formanufacturers Industry” RockwellAutomation, The major functions andobjectives of e-manufacturing are: (a) provide atransparent, seamless and automatedinformation exchange process to enable an onlyhandle information once (OHIO) environment;(b) improve the utilization of plant floor assetsusing a holistic approach combining the tools ofpredictive maintenance techniques; (c) linksentire SCM operation and asset optimization;(d) deliver customer services utilizing the latestpredictive intelligence methods and Tether-freetechnologies.

The contrast between the traditional system andthe system with e-Manufacturing is indicatedbelow.



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III. e-MANUFACTURING

e-Manufacturing can be most cogently andgenerally described as the application of theInternet to Manufacturing, further e-Manufacturing is becoming popular with theincreased use of the internet. Due thewidespread availability of the Internet; large-scale distributed projects in manufacturing arebecoming popular. It is the methodology andframework for collaborative VirtualManufacturing. For the past decade, the impactof web-based technologies has added “velocity”to the design manufacturing, and aftermarketservice of a product.

Based on a Journal, Lee J, Ni J. Infotronicsagent for tether-free prognostics. Proceedingof the AAAI Spring Symposium on

Information Refinement and Revision,March 25–27, 2002,Today’s competition in manufacturing industrydepends not just on lean manufacturing but alsoon the ability to provide customers with totalsolutions and life-cycle costs for sustainablevalue. Manufacturers are now under tremendouspressure to improve their responsiveness andefficiency in terms of product development,operations, and resource utilization with atransparent visibility of production and qualitycontrol. Lead times must be cut short to theirextreme extent to meet the changing demands ofcustomers in different regions of the world.

Products are required to be made-to-order withno or minimum inventory, requiring (a) anefficient information flow between customers,manufacturing, and product development(i.e., plant floor, suppliers, and designers), (b) atight control between customers andmanufacturing, (c) near-zero downtime of theplant floor assets.

Figure summarizes the trends in manufacturingand function of predictive intelligence as anenabling tool to meet the needs.

e-Manufacturing is a transformation system thatenables the manufacturing operations to achievepredictive near-zero-downtime performance aswell as to synchronize with the business systemsthrough the use of web-enabled and tether-freeinfotronics technologies.



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It integrated information and decision makingamong data flow (of machine/process level),information flow (of factory and supply systemlevel), and cash flow (of business system level).It is aimed to complete integration of all theelements of a business including suppliers,customer service network, manufacturingenterprise, and plant floor assets withconnectivity and intelligence brought by theweb-enabled and tether-free technologies.

Based on Society of ManufacturingEngineers (SME), Less factory downtimewith ‘predictive intelligence’, ManufacturingEngineering Journal, Feb. 2002, e-Manufacturing includes the ability to monitorthe plant floor assets, predict the variation ofproduct quality and performance loss of anyequipment for dynamic rescheduling ofproduction and maintenance operations, andsynchronize with related business services toachieve a seamless integration betweenmanufacturing and higher level enterprisesystems.

Dynamically updated information andknowledge about the capabilities, limits, andvariation of manufacturing assets for varioussuppliers guarantee the best decisions foroutsourcing at the early stages of design. Inaddition, it enables customer ordersautonomously across the supply chain, bringingunprecedented levels of speed, flexibility, andvisibility to the production process reducinginventory, excess capacity, and uncertainties.

The intrinsic value of an e-Manufacturingsystem is to enable real-time decision makingamong product designers, process capabilities,and suppliers as illustrated in Figure below.

e-Manufacturing is a transformation system thatenables e-Business systems to meet theincreasing demands through tightly coupledsupply chain management (SCM), enterpriseresource planning (ERP), and customer relationmanagement (CRM) systems as well asenvironmental and labor regulations andawareness. The Integration is illustrated inFigure below.

IV. e-MANUFACTURING TOOLS

Implementation of the e-Manufacturing toolsresults in cost saving, regardless of the companysize. Adapted from Lee, J., E-Intelligenceheads quality transformation, Quality inManufacturing Magazine, March/April 2001,



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e-Manufacturing tools enable connectivityamong the various modules of themanufacturing process.

Areas where the e-Manufacturing tools need tobe developed are listed below.

Prediction Tools:Apart from data being gathered, certain toolsneed to be developed, which can predict ordetect the degradation of various parts of themachine, performance loss and trend of failure.Developing a tool which monitors these aspectscould set the trend for an advanced diagnosticsystem.

Optimization Tools:As far as e-Manufacturing is concerned data canbe accessed from any part of the globe at anytime. Hence certain tools need to be developedwhich can optimize the data and provide easy toread results. For example, these tools should beable to provide the performance of a drill bit forvarious drilling operation verses time,temperature, tool tip failure with variousmaterials etc.

Data and information transformation tool:The large amounts of raw data collected duringa manufacturing process are rendered useless,unless the data is gathered and transformed intosome useful information which may be used tomonitor a system. To understand this better asimple example is taken below. Consider a CNCmachine hooked to the Internet as shown inFigure 4. It shows the way data and informationare transformed from the machine to theinternet. Here the idea is to monitor the health ofthe tool [life of the tool] fixed in the CNCmachine. This technique can also be used tocalibrate a machine from the Internet.

Synchronization Tools:This is an important tool in the e-Manufacturingenvironment, which can associate variousgroups such as customer’s suppliers andmanufacturers, where first hand informationneeds to be sent to these groups duringemergencies, for example – if tool needs areplacement or tool has worn out then theinformation is sent from first the manufacturerto the supplier and tool maker where the toolcan be assessed for performance. The newconnectivity and communications tools willboost productivity, profits, speed to market, andflexibility for those manufactures who arewilling to upgrade. Some of the commone-Manufacturing tools are SMS, e-Mail,Bluetooth, Wi-Fi, Fax and InfraredConnectivity.

V. e-MAINTENANCE

One book contribute about e-Maintenance isLee, J. and B. Wang, Computer-aidedMaintenance: Methodologies and Practices,Kluwer Academic Publishing, Dordrecht,1999, adapted from the book, Progressive plantexecutives, maintenance managers, and workplanners have always wanted to haveinformation about the condition of equipmentassets at their fingertips when they need it.Unfortunately, it typically is scattered amongseparate information systems. It is difficult toview, compile and synchronize the differentinformation types on the same computerterminal. If one wants to maximize business



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continuity by increasing device up-time andminimize the time, costs and headachesassociated with device administration he mustadopt the e-Maintenance strategy. It is anetwork that integrates and synchronizes thevarious maintenance and reliability applicationsto gather and deliver asset information where itis needed, when it is needed. Interconnectivityof the islands of maintenance and reliabilityinformation is embodied in e-Maintenance.

The e-Maintenance network can be developedfrom a collection of information islands byusing a single proprietary system, a custombridge, or by using an open systems bridge. e-Maintenance also removes the need for manualmeter readings that is your deviceadministration is virtually reduced to nil. It isestimated that 15- 40% of indirect costs ofmanufacturing is maintenance related. About50% are unnecessary corrective maintenance,which costs 10-15 times more than predictivemaintenance. Furthermore, 25% of maintenanceis preventive, which is 3-5 times moreexpensive then predictive.

An effective e-Manufacturing strategy usespredictive maintenance techniques to forecastequipment wear and predict failure. Apart fromthis, it also alerts MRO managers to unexpectedproblems. This allows managers to proactivelycorrect problems, thus maximizing the use ofmachinery and personnel while minimizingpreventive maintenance expenses.

Predicting the reliability of plant-floorequipment can be the difference between a fewminutes of preventive maintenance and hours ordays of downtime for corrective maintenance.Ultimately, predictive maintenance,computerized maintenance managementsystems or CMMS, and effective utilization ofmaintenance specialists makee-Manufacturing work.

VI. e-DIAGNOSTICS

e-Diagnostics is the reactive and proactiveremote diagnosis, maintenance and repair ofequipment by service personnel. e-Diagnosticsoffers many businesses the promise of betterequipment reliability and performance at a muchlower cost. It is the hardened, reliableacquisition of time-stamped, highspeedinformation from the tool registers and ancillarydata points, database retention and management,parsing and analysis.

A complete e-Diagnostics solution wouldinclude the following: (a) Remote capture,transmission, analysis and dissemination ofequipment performance data. (b) Remotetakeover of equipment to manipulate equipmentsettings during and after repair. (c) A trigger forreplenishing spare parts. (d) Faster and moreeffective response to field service engineeringrequests, bringing the experts remotely to theproblem. (e) Reduced equipment and processvariation, through better visibility and responseto differences in equipment performance amongmachines. (f) Preventive response to pendingequipment failures through the use of advancedprocess control (real-time multivariate statisticalanalysis). (g) Enhanced next-generation tooldevelopment through improved awareness ofdeficiencies in current equipment designs.



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Traditional e-Diagnostics systems monitor toolperformance and provide "maintenance needed"alerts to service and engineering personnel.Much more can be derived from the rich sensordata generated as wafers pass through processchambers. This step in e-Diagnostics is toemploy proven enterprise data mining (EDM)techniques to correlate device yield andperformance with the vast amount of tool-leveland wafer-level chamber sensor data. With thisnew approach, yield and process-level issuescan be uncovered down to a particular sensorreading on a specific tool process chamber.Once a specific tool issue can be identified tohave an impact on process results, specific e-Diagnostics monitors can betargeted to prevent future yield and processexcursions, completing a closed loop processlearning effort. The steps to be followed toimplement the e-Diagnostics strategy in anindustry are as shown below.

VII. e-BUSINESS

In today’s world it’s the “Time Factor” that canmake or break an industry. Gone are the days ofbuying different applications from a host oftechnology vendors and spending countlessmonths and dollars integrating them.Increasingly, the customers are demanding morecustomized products, faster delivery schedules,and instant access to order status. Results haveto be assessed in financial terms, with return onnet assets or return on capital employed, the key

measure. e-Business promises a solution to thiscustomer demanding market.

Adapted from “Maintenance is not asmundane as it sounds Manufacturing News ,8(21), Nov. 30, 2001, Automated schedulingprovides a better method of managingproduction orders and increases the visibility ofcurrent and future scheduling activities.Tracking involves the collection, analysis,viewing and reporting of production data. To getthe best productivity from the assets deployed,three main areas need to be addressed:Condition based maintenance; computerizedmaintenance management; e-Procurement.Condition-based maintenance predicts thedeterioration of assets that allows the planningof maintenance actions more effectively andmonitors the effectiveness of the maintenanceprogramme.

Computerized maintenance managementsystems optimize the deployment of allmaintenance, repair, and operating (MRO)resources, such as people, spare parts, tools andfacilities, and allow the creation of a plannedmaintenance programme for all assets. e-Procurement allows the replacement of stockwith information and offers direct access tospares at lowest cost.

For the successful application of e-Manufacturing there must exist a partnershipbetween the supplier and the customer. The goalis to deploy best practices in e-businessprocesses as quickly and effectively as possiblewhile ensuring a quantifiable return oninvestment (ROI).

Lee J, Ni J. E-manufacturing and e-businessintegration: a case study. Proceeding of theInternational Manufacturing Leaders Forum(IMLF), Adelaide, Australia, February 8–10,2002 have studied about the benefits of adoptinge-business strategy are;



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(a) Quick installation of software updates withno need for expensive integration projects. (b)One enterprise wide view of the customer,product or process. (c) Global deployment fromone instance of the software, making allapplications accessible globally via a standardWeb browser. (d) Simplified systems andmaintenance for IT staff due to the one-vendorapproach. (e) Streamlined business processes.(f) Better decision-making and businessintelligence because of the single-databasearchitecture and preintegrated applications andrapid deployment at lower cost.

VIII. BENEFITS OF e-MANUFACTURING

e-Manufacturing is a fundamental change in thestrategic value proposition for manufacturers.Studied by Jay Lee in a Journal entitle ‘E –Manufacturing Review – Robotics andComputer Integrated Manufacturing, May23 – 2003, Its collection of systems, processes,and technologies that support and enablemanufacturers to compete in collaboration withothers has seven fundamental jobs:1. Synchronize Production Processes withBusiness Processes.2. Orchestrate Upstream Flows of Work,Information, and Material.3. Automate Business Processes & Workflowswithin the Enterprise

4. Give Control to Managers with PlantInformation & Analysis Tools.5. Integrate the Design Process among AllCollaborating Parties.

6. Leverage Bi-directional Down-streamInformation.7. Enable Collaborative Maintenance andManufacturing Support.

IX. CONCLUSION

This paper discussed certain key areas andsubsets of the e-Manufacturing strategy whichwhen implemented will yield priceless benefitsto an industry that implements it.

e-Manufacturing is a new manufacturingconcept under current situation. It is effectiveenterprise technologies of integrating all kindsof heterogeneous systems from plant floorsources to suppliers and customers by electronicand Web technologies. Further the concept of ane-Factory promises greater increase inproductivity and performance, while at the sametime decreases production costs. However, fore-Manufacturing to be a success, co-operationbetween various public and private sectororganizations is mandatory. This new thinkingparadigm to integrate web-enabled andpredictive intelligence for manufacturingsystems is becoming a new benchmark strategyfor manufacturing companies to compete in thetwenty-first century.

REFERENCES

[1] Journal “Making sense of E-Manufacturing:A Road map for manufacturers Industry”Rockwell Automation.

[2] Exploiting E Manufacturing: Interoperabilityof Software Systems used by US Manufacturing“ National Coalition for AdvancedManufacturing, 2001, pp 1-13



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[3] Manufacturing Engineering Handbook – byHwaiyu Geng, McGraw Hill Professional 1edition, March 1, 2004,

[4] Koc M, Ni J, Lee J. Introduction of e-manufacturing. Proceeding of the InternationalConference on Frontiers on Design andManufacturing, Dalian, China, July 2002.

[5] E – Manufacturing Review – Jay Lee –Robotics and Computer IntegratedManufacturing Journal., May 23 – 2003

[6] Lee J, Ahad A, Ko@ M. E-manufacturing—its elements and impact. Proceedings of theAnnual Institute of Industrial Engineering (IIE)Conference, May 21–23, 2001.

[7] Lee J, Ni J. Web-enabled e-manufacturing.Proceeding of Sixth International ManufacturingTechnology in Hong Kong, December 2001

[8] Lee J, Ni J. E-manufacturing and e-businessintegration: a case study. Proceeding of theInternational Manufacturing Leaders Forum(IMLF), Adelaide, Australia, February 8–10,2002.

[9] Lee J, Ni J. Infotronics agent for tether-freeprognostics. Proceeding of the AAAI SpringSymposium on Information Refinement andRevision, March 25–27, 2002.

[10] Wong, Y. and S. Athanasios, Learningconvergence in the CMAC, IEEE Transactionson Neural Networks, 3, 115, 1992.

[11] Lee, J. and B. Wang, Computer-aidedMaintenance: Methodologies and Practices,Kluwer Academic Publishing, Dordrecht, 1999.

[12] Lee, J., Machine Performance AssessmentMethodology and Advanced ServiceTechnologies, Report of Fourth AnnualSymposium on Frontiers of Engineering,National Academy Press, Washington, DC,1999, pp. 75–83.

[13] Lee, J. and B.M. Kramer, Analysis ofmachine degradation using a neural networks

based pattern discrimination model, Journal ofManufacturing Systems, 12, 379–387, 1992.

[14] Maintenance is not as mundane as it soundsManufacturing News, 8(21), Nov. 30, 2001.

http://www.manufacturingnews.com/news/01/1130/art1.html.

[15] Society of Manufacturing Engineers(SME), Less factory downtime with ‘predictiveintelligence’, Manufacturing EngineeringJournal, Feb. 2002, www.sme.org.

[16] Lee, J., E-Intelligence heads qualitytransformation, Quality in ManufacturingMagazine, March/April 2001,www.manufacturingcenter.com.



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Computer Applications in Manufacturing Systems, 2009

Engineering

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